Extension Housing Gasket: Installation

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.

Install a new extension housing gasket.

Fig 1: Locating Extension Housing Gasket
Courtesy of FORD MOTOR CO.
Install the extension housing and the transmission extension housing-to-case bolts.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 2: Locating Extension Housing-To-Case Bolts
  Courtesy of FORD MOTOR CO.
Inspect the new output shaft nut O-ring for cuts. If cut, install a new output shaft nut.

Fig 3: Locating Output Shaft Nut O-Ring
Courtesy of FORD MOTOR CO.
Using the Output Shaft Locknut Socket, install a new output shaft retaining nut.
- Tighten to 200 Nm (148 lb-ft).
  
  Fig 4: Removing\Installing Output Shaft Nut Using Output Shaft Locknut Socket
  Courtesy of FORD MOTOR CO.
Connect the OSS sensor.

Fig 5: Locating Output Shaft Speed (OSS) Sensor Connector
Courtesy of FORD MOTOR CO.
If required, install new transmission insulator studs.
- Tighten to 75 Nm (55 lb-ft).
Install the transmission insulator and the new transmission insulator-to-extension housing bolts.
- Tighten to 103 Nm (76 lb-ft).
  
  Fig 6: Locating Transmission Insulator Bolts
  Courtesy of FORD MOTOR CO.
Install the transmission support crossmember. For additional information, refer to FULL FRAME & BODY MOUNTING .
RWD vehicles
Install the output shaft flange and a new output shaft flange bolt.
- Tighten to 130 Nm (96 lb-ft).
  
  Fig 7: Locating Output Shaft Flange Bolt
  Courtesy of FORD MOTOR CO.
NOTE: Align index marks made during removal.

NOTE: Install new bolts and retainers.

Install the 4 new driveshaft-to-transmission flange bolts.
- Tighten to 100 Nm (74 lb-ft).
  
  Fig 8: Locating Driveshaft Mechanic's Wire
  Courtesy of FORD MOTOR CO.
4WD vehicles
Install the transfer case. For additional information, refer to TRANSFER CASE .
All vehicles
Start the engine. Move the selector lever through all the gear ranges, checking for engagements.
NOTE: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or transmission failure.

Using the scan tool with the engine running, check and make sure the transmission is at normal operating temperature 66-77°C (150-170°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.